Control cables

Control cables are essential components in industrial automation systems. Ngoc Lan Cable applies leading international technical standards in product manufacturing and development. This article will provide a comprehensive look at control cables, including:

• • Detailed definitions and roles
  • In-depth technical construction
  • Classifications and practical applications
  • Important quality standards
  • Professional product selection guidance

Ngoc Lan Cable commits to providing control cable solutions meeting TCVN 6610 (IEC 60227) and TCVN 5935 standards for all industrial applications.

1. What is a control cable?

Control cables (also known as signal cables) are specialized cables designed to transmit low-voltage signals (450/750V) from machinery to remote control devices. These cables play a vital role in operating critical systems such as:

• • Industrial automation
  • Building fire alarm systems
  • Audio systems
  • Air conditioning systems
  • Infrastructure management

Control cables are particularly important when the distance between transmitting and receiving devices is too far for electromagnetic waves, ensuring accurate and stable signal transmission.

2. Control cable construction

To better understand the specialized structure of control cables, we will analyze each important component in detail. From the conducting core to the outer protective layer, every detail is designed for accurate and safe signal transmission.

2.1 Conductor

The conductor is critical in the control cable structure, responsible for accurate and stable signal transmission. At Ngoc Lan Cable, we use pure copper with over 99.9% purity (red copper), minimizing energy loss and improving transmission efficiency. The technical structure of the conducting core is designed to international standards with key specifications:

• • Control cable cross-section: From 0.5mm² to 2.5mm²
  • Number of cores: 2 to 61 cores (cores twisted with PP filler and PET tape)
  • Continuous operating temperature: Maximum 70°C
  • Maximum short-circuit temperature: Up to 160°C

With its flexible multi-core structure, our control cables ensure high reliability in complex industrial applications, from automation systems to precision measuring equipment.

2.2 Insulation layer

The insulation layer plays an important role in separating and protecting the conducting cores. We use high-quality insulating materials like PVC and XLPE, offering advantages such as:

• • Good heat resistance
  • High dielectric strength
  • Moisture and corrosion resistance
  • Meets IEC 60227 insulation standards

2.3 Shielding screen

The shielding screen (if required) is an important "armor" for signal transmission. At Ngoc Lan Cable, we apply advanced shielding technology:

• • Shielding layer made of copper or aluminum mesh, or braided copper wires.
  • EMI (ElectroMagnetic Interference) shielding capability depends on specific frequency and environmental conditions)

2.4 Outer sheath

The outer sheath is made of PVC or HDPE, providing the cable with advantages like:

• • High mechanical strength
  • Corrosion and environmental resistance

The cable layers are designed and rigorously tested to ensure signal transmission integrity under the harshest industrial conditions.

3. Control cable classifications

Based on specific technical criteria, control cables are classified to meet various technical requirements in industrial systems. Let's explore each technical criterion from the number of cores to shielding capabilities and sheath characteristics..

3.1 Classification by number of cores

The number of cores classification helps determine signal transmission capabilities and control system complexity. Each core represents a separate signal or control function, allowing engineers to select solutions that match specific technical requirements. Ngoc Lan Cable provides product lines with diverse core counts:

• • 2 to 12 cores: Used for simple control systems
  • 16 to 24 cores: Suitable for medium complexity control systems
  • 30 to 61 cores: Designed for complex and multi-functional control systems

3.2 Classification by shielding capability

Shielding capability is a critical factor determining signal transmission quality in industrial environments. This classification helps ensure signal stability and control accuracy. Based on electromagnetic interference (EMI) protection, cables are divided into: Unshielded cables:

• • Suitable for low EMI environments
  • Lower cost
  • Applications in simple systems

Shielded cables:

• • Equipped with copper or aluminum mesh screening
  • Effective interference protection in industrial environments
  • High signal stability assurance
  • Applications in complex control systems

3.3 Classification by outer sheath

The outer sheath determines environmental resistance and control cable lifespan. Selecting appropriate materials is critical in ensuring system performance and durability. Based on materials and environmental resistance:

• PVC-sheathed cables:
  • Temperature resistance from -10°C to 70°C
  • Lower cost
  • Widely used in office and factory environments
• XLPE-sheathed cables:
  • Temperature resistance from -40°C to 90°C
  • Excellent heat and corrosion resistance
  • Applications in harsh environments
• Flame-retardant control cables:
  • High temperature resistance using silicone rubber mix for insulation and flame retardance
  • Flame spread limitation at fault points
  • Applications in safety systems and fire risk prevention

Each type of control cable is designed and manufactured by NGC Cable with high technical standards, ensuring quality and reliability across all applications.

4. Control cable applications in daily life

In modern industrial settings, control cables play a vital role in connecting and transmitting signals between complex technical systems (PLC, CNC...). Let's explore the specialized applications of control cables, focusing on analyzing technical requirements and accurate signal transmission solutions in important industrial sectors.

4.1 Industrial applications

The manufacturing environment presents high technical challenges for signal transmission systems. From robotic systems to automated production lines incorporating frequency inverters for motor speed control, each application requires specialized control cable solutions. We'll analyze two key applications: robotic control systems and automated production systems.

4.1.1 Robotic control systems

Industrial robotic systems clearly demonstrate the importance of high-quality control cables. Every robot movement depends on signal transmission accuracy. From welding robots in automotive manufacturing to electronic assembly robots, technical requirements are extremely stringent. Key technical specifications:

• • Number of cores: 4 to 24 cores (up to 61 cores for more complex systems)
  • Shielding capability: High grade
  • Mechanical durability: Withstands continuous impact forces

4.1.2 Automated production systems

Modern production lines are complex systems requiring perfect signal transmission solutions. Control cables manage central electrical cabinet connections and synchronize equipment accurately. Technical challenges in ensuring production process continuity will be analyzed in detail. Technical criteria:

• • Maximum continuous operating temperature of 70°C
  • Shielding capability: Specialized metal screening

4.2 Infrastructure and construction applications

Modern buildings require control systems with optimal safety. Control cables become vital solutions in connecting complex systems. We'll focus on analyzing two important applications: elevator systems and fire alarm systems.

4.2.1 Elevator Systems

Elevators are typical applications demanding absolute accuracy and safety. Every movement depends entirely on signal transmission system quality. Specific technical requirements will be analyzed in detail to understand control cables' role. Technical requirements:

• • Number of cores: 10 to 16 cores (24-36 cores for more complex elevator systems)
  • Flame spread resistance capability

4.2.2 Fire Alarm and Security Systems

Security is vital in modern buildings. Fire alarm systems play an important role in protecting lives and property. Technical details about control cables will be clarified to understand the importance of signal transmission solutions. Technical characteristics:

• • Specialized interference-resistant cores
  • Long-distance signal transmission: Up to 1000m under ideal conditions
  • Sensitivity: Rapid event detection

5. Control cable quality standards

Quality standards are critical factors determining control cable reliability in complex industrial systems. We'll analyze in detail the IEC, TCVN standards and important technical requirements in the wire and cable industry.

5.1 IEC (International Electrotechnical Commission) Standards

IIEC is the leading international standardization organization in electrical and electronic fields. IEC standards set strict requirements for control cable quality. Key points in IEC standards include:

• • IEC 60227: Standard for PVC cables
  • IEC 60332-1: Flame retardance standard
  • IEC 60754: Corrosive gas testing
  • IEC 61034: Smoke measurement during combustion

5.2 TCVN (Vietnam National Standards)

TCVN standards are developed to suit Vietnam's practical conditions, ensuring product quality matches local environmental and technical requirements. Important standards include:

• • TCVN 5935: Wire and cable standards
  • TCVN 7305-1: Fire safety regulations
  • TCVN 9385: Technical standards for insulation

6. Benefits of using high-quality control cables

When using high-quality control cables, industrial systems show significantly improved durability and signal transmission efficiency during operation. Below we'll analyze two key benefits: durability and safety, and signal transmission efficiency.

6.1 Durability and safety

Durability and safety determine the lifespan and reliability of signal transmission systems. High-quality products offer important technical advantages:

• • Maximum continuous operating temperature of 70°C and short-circuit temperature resistance up to 160°C
  • Effective flame spread resistance at fault points, protecting systems during fire incidents
  • Chemical corrosion resistance suitable for harsh industrial environments
  • High mechanical strength withstanding continuous impact forces
  • Long service life depending on environmental conditions and usage

6.2 Signal transmission efficiency

Accurate signal transmission is vital for industrial control systems. Technical solutions enhancing efficiency include:

• • Pure copper cores with over 99.9% purity ensuring optimal electrical conductivity
  • Specialized EMI protection system with shielding layer
  • Stable signal transmission capability up to 1000m under ideal conditions
  • Quick event detection sensitivity suitable for modern automation systems
  • Minimized energy loss ensuring good transmission efficiency

7. Guide to selecting appropriate control cables

Selecting the right control cable is a complex technical process requiring in-depth analysis. Let's explore five essential criteria helping technical experts make accurate decisions.

7.1 Evaluating working environment

The operating environment is the primary determining factor in control cable selection. Each technical detail of the environment directly affects cable performance. Technical factors to consider include:

• • Continuous operating temperature (from -40°C to 70°C)
  • Chemical corrosion level
  • Mechanical impact risk
  • Electromagnetic interference density
  • Industrial environment pressure

7.2 Signal transmission technical requirements

Each signal transmission technical parameter determines the control system's operational capability. Let's analyze the important technical characteristics in detail. Parameters to evaluate:

• • Signal transmission distance (maximum 1000m)
  • Number of conducting cores (2 to 61 cores)
  • Transmission speed
  • Event detection sensitivity
  • Operating voltage (450/750V)

7.3 Shielding characteristics

Electromagnetic interference protection is a crucial solution for protecting signals in complex industrial environments. Key factors include:

• • Specialized metal screening layer
  • Shielding coefficient
  • Signal protection capability in high-interference environments
  • Pure copper core usage (purity over 99.9%)

7.4 Technical standards

Compliance with international and local standards ensures system quality and safety. Let's explore important technical certifications. Main standards:

• • IEC 60227 (cable standard)
  • TCVN 5935 (Vietnam standard)
  • ISO 9001:2015 (quality management system)
  • QUATEST 3 certification

7.5 Durability and lifespan

Evaluating cable resilience under harsh working conditions helps experts select optimal solutions. Assessment factors include:

• • Mechanical durability
  • Flame spread resistance
  • Expected lifespan
  • Maintenance conditions
  • Lifecycle cost

8. Common issues when using control cables

During industrial system operations, technical experts often face challenges related to control cables. Let's analyze common technical issues and effective solutions.

8.1 Technical issues

Control cable systems in industrial environments always contain technical risks requiring high attention and expertise. Common issues directly affect signal transmission efficiency and system lifespan. Important technical issues include:

• • Insulation degradation due to high temperatures
  • Outer sheath corrosion in harsh environments
  • EMI reducing signal quality
  • Mechanical wear from impact and vibration
  • Reduced dielectric strength over time
  • Connection faults causing contact resistance loss

8.2 Solutions

To ensure stable system operation, technical experts should apply professional solutions:

• • Perform regular insulation strength tests
  • Use specialized anti-corrosion sheathing
  • Install modern interference protection systems
  • Protect cables with mechanical solutions
  • Use professional connection solutions
  • Replace cables periodically according to manufacturer recommendations

9. Frequently asked questions (FAQs)

Control cables are complex technical solutions, generating many questions from experts and users. We'll address the most important questions.

9.1 What is a shielded control cable?

A shielded control cable is equipped with a metal screening layer (usually copper or aluminum mesh) to block electromagnetic interference affecting signal transmission. This screening helps protect signals for accurate and stable transmission.

9.2 Comparing shielded and unshielded control cables

Shielded cables:

• • Advantage: Stable signal transmission
  • Suitable for: Complex industrial environments
  • Cost: Higher

Unshielded cables:

• • Advantage: Lower cost
  • Suitable for: Low interference environments
  • Limitation: Susceptible to electromagnetic interference

9.3 Why use high-quality control cables?

High-quality control cables ensure:

• • High signal transmission reliability
  • System safety
  • Long service life
  • Minimized risk of failures
  • Optimal operational efficiency

10. Conclusion

Control cables are technical solutions for signal transmission in industrial systems. Engineers and technicians need to understand key evaluation criteria including electrical durability, interference resistance, and environmental compatibility. For experienced engineers, control cable selection requires in-depth analysis of each project's specific requirements. For students and new electricians, understanding the basic structure and applications serves as an important foundation. Technical standards such as IEC and TCVN provide implementation guidance. Engineers must accurately calculate parameters including transmission distance, operating voltage, and environmental conditions. For questions about control cable selection and usage, consult electrical or technical experts to ensure appropriate solutions.